U.S. patent application number 13/645343 was filed with the patent office on 2013-01-31 for material elements incorporating tensile strands.
This patent application is currently assigned to NIKE, Inc.. The applicant listed for this patent is NIKE, Inc.. Invention is credited to Frederick J. Dojan, Chin-Chen Huang, James C. Meschter.
Application Number | 20130025159 13/645343 |
Document ID | / |
Family ID | 43499593 |
Filed Date | 2013-01-31 |
United States Patent
Application |
20130025159 |
Kind Code |
A1 |
Dojan; Frederick J. ; et
al. |
January 31, 2013 |
Material Elements Incorporating Tensile Strands
Abstract
An article of footwear or other product may include a material
element having a first layer, a second layer, a third layer, and at
least one strand. The second layer is positioned between the first
layer and the third layer, and the second layer is formed from a
thermoplastic polymer material. The strand is located between the
first layer and the second layer, and the strand lies substantially
parallel to the second layer for a distance of at least five
centimeters. In this configuration, the thermoplastic polymer
material may join the first layer and the third layer to the second
layer. The thermoplastic polymer material may also join the strand
to the second layer.
Inventors: |
Dojan; Frederick J.;
(Vancouver, WA) ; Huang; Chin-Chen; (Taichung,
TW) ; Meschter; James C.; (Portland, OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc.; |
Beaverton |
OR |
US |
|
|
Assignee: |
NIKE, Inc.
Beaverton
OR
|
Family ID: |
43499593 |
Appl. No.: |
13/645343 |
Filed: |
October 4, 2012 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12505740 |
Jul 20, 2009 |
8312645 |
|
|
13645343 |
|
|
|
|
11441924 |
May 25, 2006 |
7870681 |
|
|
12505740 |
|
|
|
|
Current U.S.
Class: |
36/83 ; 156/219;
156/296; 156/93; 428/196; 428/201 |
Current CPC
Class: |
A43B 1/00 20130101; A43B
23/026 20130101; Y10T 428/24851 20150115; Y10T 428/2481 20150115;
A43B 3/26 20130101; A43B 23/0275 20130101; Y10T 428/24 20150115;
Y10T 156/1039 20150115; A43B 23/0235 20130101; A43B 5/06
20130101 |
Class at
Publication: |
36/83 ; 428/201;
428/196; 156/296; 156/93; 156/219 |
International
Class: |
A43B 1/00 20060101
A43B001/00; B32B 37/10 20060101 B32B037/10; B32B 38/00 20060101
B32B038/00; B32B 3/18 20060101 B32B003/18; B32B 37/06 20060101
B32B037/06 |
Claims
1. A material element comprising: a first layer, a second layer,
and a third layer, the second layer being positioned between the
first layer and the third layer, and the second layer being formed
from a thermoplastic polymer material; and a plurality of strands
located between the first layer and the second layer, the strands
lying substantially parallel to surfaces of the first layer and the
second layer for distances of at least five centimeters, wherein
heatbonds between the thermoplastic polymer material and each of
the first layer and third layer join the second layer to the first
layer and third layer.
2. The material element recited in claim 1, wherein heatbonds
between the thermoplastic polymer material and the strands join the
second layer to the strands.
3. The material element recited in claim 1, wherein at least one of
the first layer and the third layer are a textile material.
4. The material element recited in claim 1, wherein a first group
of the strands cross a second group of the strands.
5. The material element recited in claim 1, wherein a material of
the strand is selected from a group consisting of carbon fiber,
aramid fiber, ultra high molecular weight polyethylene, and liquid
crystal polymer.
6. The material element recited in claim 1, wherein ends of the
strands are located at an edge of the first layer and an edge of
the second layer.
7. A method of manufacturing a material element, the method
comprising: locating at least one strand adjacent to a surface of a
polymer sheet that incorporates a thermoplastic polymer material,
the strand being substantially parallel to the surface for a
distance of at least five centimeters; positioning a first layer
adjacent to the surface, the strand being located between the
polymer sheet and the first layer; and heating the first layer, the
strand, and the polymer sheet, the thermoplastic polymer material
from the polymer sheet infiltrating at least one of the first layer
and the strand to form a bond between the polymer sheet and each of
the first layer and the strand.
8. The method recited in claim 7, wherein the step of locating
includes embroidering the strand onto the polymer sheet.
9. The method recited in claim 7, wherein the step of locating
includes selecting the polymer sheet to be a layer of a
thermoplastic polymer material.
10. The method recited in claim 7, wherein the step of positioning
includes placing a second layer adjacent to an opposite surface of
the polymer layer, and the step of heating includes bonding the
second layer to the polymer sheet.
11. A method of manufacturing an element, the method comprising:
locating a plurality of strands adjacent a polymer sheet that
incorporates a thermoplastic polymer material, the strands being
substantially parallel to the polymer sheet for distances of at
least five centimeters; positioning a first layer and a second
layer on opposite sides of the polymer sheet, the strands being
located between the polymer sheet and the first layer; placing the
strands, the polymer sheet, the first layer, and the second layer
between a first surface and a second surface of a press, the first
surface and the second surface being formed from different
materials; and compressing and heating the strands, the polymer
sheet, the first layer, and the second layer between the first
surface and the second surface such that: (a) portions of the first
layer that are in contact with the strands protrude into the first
surface to a first depth, (b) portions of the second layer that are
adjacent to the strands protrude into the second surface to a
second depth, the first depth being greater than the second depth,
and (c) the thermoplastic polymer material of the polymer sheet
bonds with at least the first layer and the second layer.
12. The method recited in claim 11, wherein the step of positioning
includes selecting the first layer to be one of a textile and a
polymer sheet.
13. The method recited in claim 11, wherein the step of placing
includes selecting the different materials to have at least one of
different hardnesses, different densities, and different
thicknesses.
14. The method recited in claim 11, wherein the step of compressing
and heating includes bonding the thermoplastic polymer material of
the polymer sheet to the strands.
15. The method recited in claim 11, further including steps of (a)
incorporating the strands, the polymer sheet, the first layer, and
the second layer into an article of footwear and (b) positioning
the first layer to form a portion of an exterior surface of the
article of footwear.
16. The method recited in claim 11, further including steps of (a)
incorporating the strands, the polymer sheet, the first layer, and
the second layer into an article of footwear and (b) positioning
the second layer to be more toward an interior of the article of
footwear than the first layer.
17. An article of footwear having an upper and a sole structure
secured to the upper, at least a portion of the upper comprising: a
first layer and a second layer, at least the second layer being a
polymer sheet that defines a plurality of apertures; and at least
one strand located between the first layer and the second layer,
the strand lying substantially parallel to the second layer for a
distance of at least five centimeters.
18. The article of footwear recited in claim 17, wherein the second
layer is thermoplastic polymer material that joins the first layer
to the second layer.
19. The article of footwear recited in claim 17, wherein the
apertures of the second layer extend through the first layer.
20. The article of footwear recited in claim 17, wherein the first
layer is a textile material.
21. The article of footwear recited in claim 17, wherein a third
layer is secured to the second layer, the second layer being
located between the first layer and the third layer.
Description
CROSS-REFERENCE To RELATED APPLICATIONS
[0001] This U.S. Patent Application is a division of U.S. patent
application Ser. No. 12/505,740, entitled "Material Element
Incorporating Tensile Strands", which was filed on Jul. 20, 2009
and allowed on Sep. 19, 2012, which application is a
continuation-in-part application and claims priority under 35
U.S.C. .sctn.120 to U.S. patent application Ser. No. 11/441,924,
which was filed in the U.S. Patent and Trademark Office on May 25,
2006 and entitled "Article Of Footwear Having An Upper With Thread
Structural Elements", and which issued as U.S. Pat. No. 7,870,681
on Jan. 18, 2011, such prior U.S. Patent Applications being
entirely incorporated herein by reference.
BACKGROUND
[0002] Articles of footwear generally include two primary elements:
an upper and a sole structure. The upper is often formed from a
plurality of material elements (e.g., textiles, polymer sheet
layers, foam layers, leather, synthetic leather) that are stitched
or adhesively bonded together to form a void on the interior of the
footwear for comfortably and securely receiving a foot. More
particularly, the upper forms a structure that extends over instep
and toe areas of the foot, along medial and lateral sides of the
foot, and around a heel area of the foot. The upper may also
incorporate a lacing system to adjust fit of the footwear, as well
as permitting entry and removal of the foot from the void within
the upper. In addition, the upper may include a tongue that extends
under the lacing system to enhance adjustability and comfort of the
footwear, and the upper may incorporate a heel counter.
[0003] The various material elements forming the upper impart
different properties to different areas of the upper. For example,
textile elements may provide breathability and may absorb moisture
from the foot, foam layers may compress to impart comfort, and
leather may impart durability and wear-resistance. As the number of
material elements increases, the overall mass of the footwear may
increase proportionally. The time and expense associated with
transporting, stocking, cutting, and joining the material elements
may also increase. Additionally, waste material from cutting and
stitching processes may accumulate to a greater degree as the
number of material elements incorporated into an upper increases.
Moreover, products with a greater number of material elements may
be more difficult to recycle than products formed from fewer
material elements. By decreasing the number of material elements,
therefore, the mass of the footwear and waste may be decreased,
while increasing manufacturing efficiency and recyclability.
[0004] The sole structure is secured to a lower portion of the
upper so as to be positioned between the foot and the ground. In
athletic footwear, for example, the sole structure includes a
midsole and an outsole. The midsole may be formed from a polymer
foam material that attenuates ground reaction forces (i.e.,
provides cushioning) during walking, running, and other ambulatory
activities. The midsole may also include fluid-filled chambers,
plates, moderators, or other elements that further attenuate
forces, enhance stability, or influence the motions of the foot,
for example. The outsole forms a ground-contacting element of the
footwear and is usually fashioned from a durable and wear-resistant
rubber material that includes texturing to impart traction. The
sole structure may also include a sockliner positioned within the
upper and proximal a lower surface of the foot to enhance footwear
comfort.
SUMMARY
[0005] An article of footwear or other product may incorporate a
material element having tensile strands. More particularly, the
material element may include a first layer, a second layer, a third
layer, and at least one strand. The second layer is positioned
between the first layer and the third layer, and the second layer
is formed from a thermoplastic polymer material. The strand is
located between the first layer and the second layer, and the
strand lies substantially parallel to the second layer for a
distance of at least five centimeters. The thermoplastic polymer
material joins the first layer and the third layer to the second
layer. The thermoplastic polymer material may also join the strand
to the second layer.
[0006] A method of manufacturing an element, which may be utilized
in the footwear, is also described below. The method includes
locating at least one strand adjacent to a surface of a polymer
sheet that incorporates a thermoplastic polymer material, with the
strand being substantially parallel to the surface for a distance
of at least five centimeters. A first layer is positioned adjacent
to the surface, and the strand is located between the polymer sheet
and the first layer. The first layer, the strand, and the polymer
sheet are heated. Upon heating, the thermoplastic polymer material
from the polymer sheet infiltrates at least one of the first layer
and the strand to form a bond between the polymer sheet and each of
the first layer and the strand.
[0007] The advantages and features of novelty characterizing
aspects of the invention are pointed out with particularity in the
appended claims. To gain an improved understanding of the
advantages and features of novelty, however, reference may be made
to the following descriptive matter and accompanying figures that
describe and illustrate various configurations and concepts related
to the invention.
FIGURE DESCRIPTIONS
[0008] The foregoing Summary and the following Detailed Description
will be better understood when read in conjunction with the
accompanying figures.
[0009] FIG. 1 is a lateral side elevational view of an article of
footwear.
[0010] FIG. 2 is a medial side elevational view of the article of
footwear.
[0011] FIG. 3 is a cross-sectional view of the article of footwear,
as defined by section line 3-3 in FIG. 2.
[0012] FIG. 4 is a plan view of a tensile strand material element
utilized in an upper of the article of footwear.
[0013] FIG. 5 is a perspective view of a portion of the tensile
strand material element, as defined in FIG. 4.
[0014] FIG. 6 is an exploded perspective view of the portion of the
tensile strand material element.
[0015] FIGS. 7A and 7B are a cross-sectional views of the portion
of the tensile strand material element, as defined by section lines
7A and 7B in FIG. 5.
[0016] FIGS. 8A-8E are lateral side elevational views corresponding
with FIG. 1 and depicting further configurations of the article of
footwear.
[0017] FIGS. 9A-9E are cross-sectional views corresponding with
FIG. 3 and depicting further configurations of the article of
footwear.
[0018] FIGS. 10A-10D are schematic perspective views of a first
example manufacturing method for the tensile strand material
element.
[0019] FIGS. 11A-11D are schematic cross-sectional views of the
first example manufacturing method, as respectively defined by
section lines 11A-11D in FIGS. 10A-10D.
[0020] FIGS. 12A-12D are schematic perspective views of a second
example manufacturing method for the tensile strand material
element.
[0021] FIGS. 13A-13D are schematic cross-sectional views of the
second example manufacturing method, as respectively defined by
section lines 13A-13D in FIGS. 12A-12D.
[0022] FIG. 14 is a cross-sectional view of another configuration
of the tensile strand material element.
[0023] FIG. 15 is a perspective view of a portion of another
configuration of a tensile strand material element.
[0024] FIG. 16 is an exploded perspective view of a portion of
another configuration of a tensile strand material element.
DETAILED DESCRIPTION
[0025] The following discussion and accompanying figures disclose a
material element incorporating tensile strands. The material
element is disclosed as being incorporated into an article of
footwear having a general configuration suitable for walking or
running. Concepts associated with the material element may also be
applied to a variety of other athletic footwear types, including
baseball shoes, basketball shoes, cross-training shoes, cycling
shoes, football shoes, tennis shoes, soccer shoes, and hiking
boots, for example. The concepts may also be applied to footwear
types that are generally considered to be non-athletic, including
dress shoes, loafers, sandals, and work boots. The concepts
disclosed herein apply, therefore, to a wide variety of footwear
types. In addition to footwear, the material element or concepts
associated with the material element may be incorporated into a
variety of other products.
[0026] General Footwear Structure
[0027] An article of footwear 10 is depicted in FIGS. 1-3 as
including a sole structure 20 and an upper 30. For reference
purposes, footwear 10 may be divided into three general regions: a
forefoot region 11, a midfoot region 12, and a heel region 13, as
shown in FIGS. 1 and 2. Footwear 10 also includes a lateral side 14
and a medial side 15. Forefoot region 11 generally includes
portions of footwear 10 corresponding with the toes and the joints
connecting the metatarsals with the phalanges. Midfoot region 12
generally includes portions of footwear 10 corresponding with the
arch area of the foot, and heel region 13 corresponds with rear
portions of the foot, including the calcaneus bone. Lateral side 14
and medial side 15 extend through each of regions 11-13 and
correspond with opposite sides of footwear 10. Regions 11-13 and
sides 14-15 are not intended to demarcate precise areas of footwear
10. Rather, regions 11-13 and sides 14-15 are intended to represent
general areas of footwear 10 to aid in the following discussion. In
addition to footwear 10, regions 11-13 and sides 14-15 may also be
applied to sole structure 20, upper 30, and individual elements
thereof.
[0028] Sole structure 20 is secured to upper 30 and extends between
the foot and the ground when footwear 10 is worn. The primary
elements of sole structure 20 are a midsole 21, an outsole 22, and
an sockliner 23. Midsole 21 is secured to a lower surface of upper
30 and may be formed from a compressible polymer foam element
(e.g., a polyurethane or ethylvinylacetate foam) that attenuates
ground reaction forces (i.e., provides cushioning) when compressed
between the foot and the ground during walking, running, or other
ambulatory activities. In further configurations, midsole 21 may
incorporate fluid-filled chambers, plates, moderators, or other
elements that further attenuate forces, enhance stability, or
influence the motions of the foot, or midsole 21 may be primarily
formed from a fluid-filled chamber. Outsole 22 is secured to a
lower surface of midsole 21 and may be formed from a wear-resistant
rubber material that is textured to impart traction. Sockliner 23
is located within upper 30 and is positioned to extend under a
lower surface of the foot. Although this configuration for sole
structure 20 provides an example of a sole structure that may be
used in connection with upper 30, a variety of other conventional
or nonconventional configurations for sole structure 20 may also be
utilized. Accordingly, the structure and features of sole structure
20 or any sole structure utilized with upper 30 may vary
considerably.
[0029] Upper 30 defines a void within footwear 10 for receiving and
securing a foot relative to sole structure 20. The void is shaped
to accommodate the foot and extends along the lateral side of the
foot, along the medial side of the foot, over the foot, around the
heel, and under the foot. Access to the void is provided by an
ankle opening 31 located in at least heel region 13. A lace 32
extends through various lace apertures 33 and permits the wearer to
modify dimensions of upper 30 to accommodate the proportions of the
foot. More particularly, lace 32 permits the wearer to tighten
upper 30 around the foot, and lace 32 permits the wearer to loosen
upper 30 to facilitate entry and removal of the foot from the void
(i.e., through ankle opening 31). In addition, upper 30 may include
a tongue (not depicted) that extends under lace 32.
[0030] The various portions of upper 30 may be formed from one or
more of a plurality of material elements (e.g., textiles, polymer
sheets, foam layers, leather, synthetic leather) that are stitched
or bonded together to form the void within footwear 10. Upper 30
may also incorporate a heel counter that limits heel movement in
heel region 13 or a wear-resistant toe guard located in forefoot
region 11. Although a variety of material elements or other
elements may be incorporated into upper, areas of one or both of
lateral side 14 and medial side 15 incorporate various strands 34.
Referring to FIGS. 1 and 2, a plurality of strands 34 extend in a
generally vertical direction between lace apertures 33 and sole
structure 20, and various strands 34 extend in a generally
horizontal direction between forefoot region 11 and heel region 13
in both of lateral side 14 and medial side 15. Referring also to
FIG. 3, the various strands 34 are located between a base layer 41
and a cover layer 42. Whereas base layer 41 forms a surface of the
void within upper 30, cover layer 42 forms a portion of an exterior
or exposed surface of upper 30. The combination of strands 34, base
layer 41, and cover layer 42 may, therefore, form substantially all
of the thickness of upper 30 in some areas.
[0031] During walking, running, or other ambulatory activities, a
foot within the void in footwear 10 may tend to stretch upper 30.
That is, many of the material elements forming upper 30 may stretch
when placed in tension by movements of the foot. Although strands
34 may also stretch, strands 34 generally stretch to a lesser
degree than the other material elements forming upper 30 (e.g.,
base layer 41 and cover layer 42). Each of strands 34 may be
located, therefore, to form structural components in upper 30 that
resist stretching in specific directions or reinforce locations
where forces are concentrated. As an example, the various strands
34 that extend between lace apertures 33 and sole structure 20
resist stretch in the medial-lateral direction (i.e., in a
direction extending around upper 30). These strands 34 are also
positioned adjacent to and radiate outward from lace apertures 33
to resist stretch due to tension in lace 32. Given that these
strands also cross each other, forces from the tension in lace 32
or from movement of the foot may be distributed over various areas
of upper 30. As another example, the various strands 34 that extend
between forefoot region 11 and heel region 13 resist stretch in a
longitudinal direction (i.e., in a direction extending through each
of regions 11-13). Accordingly, strands 34 are located to form
structural components in upper 30 that resist stretch.
[0032] Tensile Strand Material Element
[0033] A tensile strand material element 40 that may be
incorporated into upper 30 is depicted in FIG. 4. Additionally, a
portion of material element 40 is depicted in each of FIGS. 5-7B.
Material element 40 may form, for example, a majority of lateral
side 14. As a result, material element 40 has a configuration that
(a) extends from upper to lower areas of lateral side 14 and
through each of regions 11-13, (b) defines the various lace
apertures 33 in lateral side 14, and (c) forms both an interior
surface (i.e., the surface that contacts the foot or a sock worn by
the foot when footwear 10 is worn) and an exterior surface (i.e.,
an outer, exposed surface of footwear 10). A substantially similar
element may also be utilized for medial side 15. In some
configurations of footwear 10, material element 40 may only extend
through a portion of lateral side 14 (e.g., limited to midfoot
region 12) or may be expanded to form a majority of lateral side 14
and medial side 15. That is, a single element having the general
configuration of material element 40 and including strands 34 and
layers 41 and 42 may extend through both lateral side 14 and medial
side 15. In other configurations, additional elements may be joined
to material element 40 to form portions of lateral side 14.
[0034] Material element 40 includes base layer 41 and cover layer
42, with strands 34 being positioned between layers 41 and 42.
Strands 34 lie adjacent to a surface of base layer 41 and
substantially parallel to the surface of base layer 41. In general,
strands 34 also lie adjacent to a surface of cover layer 42 and
substantially parallel to the surface of cover layer 42. As
discussed above, strands 34 form structural components in upper 30
that resist stretch. By being substantially parallel to the
surfaces of base layer 41 and cover layer 42, strands 34 resist
stretch in directions that correspond with the surfaces of layers
41 and 42. Although strands 34 may extend through base layer 41
(e.g., as a result of stitching) in some locations, areas where
strands 34 extend through base layer 41 may permit stretch, thereby
reducing the overall ability of strands 34 to limit stretch. As a
result, each of strands 34 generally lie adjacent to a surface of
base layer 41 and substantially parallel to the surface of base
layer 41 for distances of at least twelve millimeters, and may lie
adjacent to the surface of base layer 41 and substantially parallel
to the surface of base layer 41 throughout distances of at least
five centimeters or more.
[0035] Base layer 41 and cover layer 42 are depicted as being
coextensive with each other. That is, layers 41 and 42 may have the
same shape and size, such that edges of base layer 41 correspond
and are even with edges of cover layer 42. In some manufacturing
processes, (a) strands 34 are located upon base layer 42, (b) cover
layer 42 is bonded to base layer 41 and strands 34, and (c)
material element 40 is cut from this combination to have the
desired shape and size, thereby forming common edges for base layer
41 and cover layer 42. In this process, ends of strands 34 may also
extend to edges of layers 41 and 42. Accordingly, edges of layers
41 and 42, as well as ends of strands 34, may all be positioned at
edges of material element 40.
[0036] Each of base layer 41 and cover layer 42 may be formed from
any generally two-dimensional material. As utilized with respect to
the present invention, the term "two-dimensional material" or
variants thereof is intended to encompass generally flat materials
exhibiting a length and a width that are substantially greater than
a thickness. Accordingly, suitable materials for base layer 41 and
cover layer 42 include various textiles, polymer sheets, or
combinations of textiles and polymer sheets, for example. Textiles
are generally manufactured from fibers, filaments, or yarns that
are, for example, either (a) produced directly from webs of fibers
by bonding, fusing, or interlocking to construct non-woven fabrics
and felts or (b) formed through a mechanical manipulation of yarn
to produce a woven or knitted fabric. The textiles may incorporate
fibers that are arranged to impart one-directional stretch or
multi-directional stretch, and the textiles may include coatings
that form a breathable and water-resistant barrier, for example.
The polymer sheets may be extruded, rolled, or otherwise formed
from a polymer material to exhibit a generally flat aspect.
Two-dimensional materials may also encompass laminated or otherwise
layered materials that include two or more layers of textiles,
polymer sheets, or combinations of textiles and polymer sheets. In
addition to textiles and polymer sheets, other two-dimensional
materials may be utilized for base layer 41 and cover layer 42.
Although two-dimensional materials may have smooth or generally
untextured surfaces, some two-dimensional materials will exhibit
textures or other surface characteristics, such as dimpling,
protrusions, ribs, or various patterns, for example. Despite the
presence of surface characteristics, two-dimensional materials
remain generally flat and exhibit a length and a width that are
substantially greater than a thickness. In some configurations,
mesh materials or perforated materials may be utilized for either
or both of layers 41 and 42 to impart greater breathability or air
permeability.
[0037] Strands 34 may be formed from any generally one-dimensional
material. As utilized with respect to the present invention, the
term "one-dimensional material" or variants thereof is intended to
encompass generally elongate materials exhibiting a length that is
substantially greater than a width and a thickness. Accordingly,
suitable materials for strands 34 include various filaments,
fibers, yarns, threads, cables, or ropes that are formed from
rayon, nylon, polyester, polyacrylic, silk, cotton, carbon, glass,
aramids (e.g., para-aramid fibers and meta-aramid fibers), ultra
high molecular weight polyethylene, liquid crystal polymer, copper,
aluminum, and steel. Whereas filaments have an indefinite length
and may be utilized individually as strands 34, fibers have a
relatively short length and generally go through spinning or
twisting processes to produce a strand of suitable length. An
individual filament utilized in strands 34 may be formed form a
single material (i.e., a monocomponent filament) or from multiple
materials (i.e., a bicomponent filament). Similarly, different
filaments may be formed from different materials. As an example,
yarns utilized as strands 34 may include filaments that are each
formed from a common material, may include filaments that are each
formed from two or more different materials, or may include
filaments that are each formed from two or more different
materials. Similar concepts also apply to threads, cables, or
ropes. The thickness of strands 34 may also vary significantly to
range from 0.03 millimeters to more than 5 millimeters, for
example. Although one-dimensional materials will often have a
cross-section where width and thickness are substantially equal
(e.g., a round or square cross-section), some one-dimensional
materials may have a width that is greater than a thickness (e.g.,
a rectangular, oval, or otherwise elongate cross-section). Despite
the greater width, a material may be considered one-dimensional if
a length of the material is substantially greater than a width and
a thickness of the material.
[0038] As examples, base layer 41 may be formed from a textile
material and cover layer 42 may be formed from a polymer sheet that
is bonded to the textile material, or each of layers 41 and 42 may
be formed from polymer sheets that are bonded to each other. In
circumstances where base layer 41 is formed from a textile
material, cover layer 42 may incorporate thermoplastic polymer
materials (e.g., thermoplastic polyurethane) that bond with the
textile material of base layer 41. That is, by heating cover layer
42, the thermoplastic polymer material of cover layer 42 may bond
with the textile material of base layer 41. As an alternative, a
thermoplastic polymer material may infiltrate or be bonded with the
textile material of base layer 41 in order to bond with cover layer
42. That is, base layer 41 may be a combination of a textile
material and a thermoplastic polymer material. An advantage of this
configuration is that the thermoplastic polymer material may
rigidify or otherwise stabilize the textile material of base layer
41 during the manufacturing process of material element 40,
including portions of the manufacturing process involving lying
strands 34 upon base layer 41. Another advantage of this
configuration is that a backing layer (see backing layer 37 in FIG.
9D) may be bonded to base layer 41 opposite cover layer 42 using
the thermoplastic polymer material in some configurations. This
general concept is disclosed in U.S. patent application Ser. No.
12/180,235, which was filed in the U.S. Patent and Trademark Office
on 25 Jul. 2008 and entitled Composite Element With A Polymer
Connecting Layer, such prior application being entirely
incorporated herein by reference. As a further alternative, base
layer 41 may be a sheet of thermoplastic polymer material (e.g.,
thermoplastic polyurethane) that bonds with cover layer 42 and
strands 34 during the manufacturing of material element 40. That
is, by heating base layer 41, the thermoplastic polymer material of
base layer 41 may bond with either or both of cover layer 42 and
strands 34.
[0039] Based upon the above discussion, material element 40
generally includes at least two layers 41 and 42 with strands 34
located between. Although strands 34 may pass through one of layers
41 and 42, strands 34 generally lie adjacent to surfaces of layers
41 and 42 and substantially parallel to the surfaces layers 41 and
42 for more than twelve millimeters and even more than five
centimeters. Whereas a variety of one dimensional materials may be
used for strands 34, one or more two dimensional materials may be
used for layers 41 and 42. Moreover, when base layer 41 is formed
as a sheet of thermoplastic polymer material, heating of the
thermoplastic polymer material may cause bonding between base layer
41 and either or both of cover layer 42 and strands 34.
[0040] Structural Components
[0041] A conventional upper may be formed from multiple material
layers that each impart different properties to various areas of
the upper. During use, an upper may experience significant tensile
forces, and one or more layers of material are positioned in areas
of the upper to resist the tensile forces. That is, individual
layers may be incorporated into specific portions of the upper to
resist tensile forces that arise during use of the footwear. As an
example, a woven textile may be incorporated into an upper to
impart stretch resistance in the longitudinal direction. A woven
textile is formed from yarns that interweave at right angles to
each other. If the woven textile is incorporated into the upper for
purposes of longitudinal stretch-resistance, then only the yarns
oriented in the longitudinal direction will contribute to
longitudinal stretch-resistance, and the yarns oriented orthogonal
to the longitudinal direction will not generally contribute to
longitudinal stretch-resistance. Approximately one-half of the
yarns in the woven textile are, therefore, superfluous to
longitudinal stretch-resistance. As an extension of this example,
the degree of stretch-resistance required in different areas of the
upper may vary. Whereas some areas of the upper may require a
relatively high degree of stretch-resistance, other areas of the
upper may require a relatively low degree of stretch-resistance.
Because the woven textile may be utilized in areas requiring both
high and low degrees of stretch-resistance, some of the yarns in
the woven textile are superfluous in areas requiring the low degree
of stretch-resistance. In this example, the superfluous yarns add
to the overall mass of the footwear, without adding beneficial
properties to the footwear. Similar concepts apply to other
materials, such as leather and polymer sheets, that are utilized
for one or more of wear-resistance, flexibility, air-permeability,
cushioning, and moisture-wicking, for example.
[0042] As a summary of the above discussion, materials utilized in
the conventional upper formed from multiple layers of material may
have superfluous portions that do not significantly contribute to
the desired properties of the upper. With regard to
stretch-resistance, for example, a layer may have material that
imparts (a) a greater number of directions of stretch-resistance or
(b) a greater degree of stretch-resistance than is necessary or
desired. The superfluous portions of these materials may,
therefore, add to the overall mass and cost of the footwear,
without contributing significant beneficial properties.
[0043] In contrast with the conventional layered construction
discussed above, upper 30 is constructed to minimize the presence
of superfluous material. Base layer 41 and cover layer 42 provide a
covering for the foot, but exhibit a relatively low mass. Strands
34 are positioned to provide stretch-resistance in particular
directions and locations, and the number of strands 34 is selected
to impart the desired degree of stretch-resistance. Accordingly,
the orientations, locations, and quantity of strands 34 are
selected to provide structural components that are tailored to a
specific purpose.
[0044] For purposes of reference in the following discussion, six
strand groups 51-56 are identified in FIG. 4. Strand group 51
includes the various strands 34 extending downward from the lace
aperture 33 closest to ankle opening 31. Strand group 52 includes
the various strands 34 extending downward from the lace aperture 33
second closest to ankle opening 31. Similarly, strand groups 53-55
include the various strands 34 extending downward from other lace
apertures 33. Additionally, strand group 56 includes the various
strands 34 that extend between forefoot region 11 and heel region
13.
[0045] As discussed above, the various strands 34 that extend
between lace apertures 33 and sole structure 20 resist stretch in
the medial-lateral direction and distribute forces from lace 32.
More particularly, the various strands 34 in strand group 51
cooperatively resist stretch from the portion of lace 32 that
extends through the lace aperture 33 closest to ankle opening 31.
Strand group 51 also radiates outward when extending away from lace
aperture 33, thereby distributing the forces from lace 32 over an
area of upper 30. Similar concepts also apply to strand groups
52-55. As an additional matter, some of strands 34 from strand
groups 51-55 cross strands 34 from other strand groups 51-55. More
particularly, (a) strands 34 from strand group 51 cross strands 34
from strand group 52, (b) strands 34 from strand group 52 cross
strands 34 from each of strand groups 51 and 53, (c) strands 34
from strand group 53 cross strands 34 from each of strand groups 52
and 54, (d) strands 34 from strand group 54 cross strands 34 from
each of strand groups 53 and 55, and (e) strands 34 from strand
group 55 cross strands 34 from strand group 54. Accordingly,
strands 34 from adjacent strand groups 51-55 may cross each other.
Although one strand 34 from one of strand groups 51-55 may cross
another strand from a different one of strand groups 51-55 in some
configurations, sometimes at least two strands 34 or at least three
strands 34 may cross. An advantage of this configuration is that
forces from lace 32 at the various lace apertures 33 may be
distributed more widely throughout upper 30, and forces from lace
32 at adjacent lace apertures 33 may be distributed to areas
covered by strands 34 from other lace apertures 33. In general,
therefore, the crossing of strands 34 from different strand groups
51-55 may distribute forces from lace 32 more evenly over areas of
upper 30.
[0046] Lace apertures 33 provide one example of a lace-receiving
element from which strands 34 may extend. In other configurations
of footwear 10, metal or textile loops may be utilized in place of
lace apertures 33, hooks may be utilized in place of lace apertures
33, or grommets may define lace apertures 33. Accordingly, strands
34 may extend between a variety of lace-receiving elements and sole
structure 20 resist stretch in the medial-lateral direction and
distribute forces from lace 32.
[0047] As also discussed above, the various strands 34 that extend
between forefoot region 11 and heel region 13 resist stretch in the
longitudinal direction. More particularly, the various strands 34
in strand group 56 cooperatively resist stretch in the longitudinal
direction, and the number of strands 34 in strand group 56 are
selected to provide a specific degree of stretch-resistance through
regions 11-13. Additionally, strands 34 in strand group 56 also
cross over each of the strands 34 in strand groups 51-55 to impart
a relatively continuous stretch resistance through regions
11-13.
[0048] Depending upon the specific configuration of footwear 10 and
the intended use of footwear 10, layers 41 and 42 may be
non-stretch materials, materials with one-directional stretch, or
materials with two-directional stretch, for example. In general,
forming layers 41 and 42 from materials with two-directional
stretch provides upper 30 with a greater ability to conform with
the contours of the foot, thereby enhancing the comfort of footwear
10. In configurations where layers 41 and 42 have two-directional
stretch, the combination of strands 34 with layers 41 and 42
effectively varies the stretch characteristics of upper 30 in
specific locations. With regard to upper 30, the combination of
strands 34 with layers 41 and 42 having two-directional stretch
forms zones in upper 30 that have different stretch
characteristics, and the zones include (a) first zones where no
strands 34 are present and upper 30 exhibits two-directional
stretch, (b) second zones where strands 34 are present and do not
cross each other, and upper 30 exhibits one-directional stretch in
a direction that is orthogonal (i.e., perpendicular) to strands 34,
and (c) third zones where strands 34 are present and cross each
other, and upper 30 exhibits substantially no stretch or limited
stretch. Accordingly, the overall stretch characteristics of
particular areas of upper 30 may be controlled by presence of
strands 34 and whether strands 34 cross each other.
[0049] Based upon the above discussion, strands 34 may be utilized
to form structural components in upper 30. In general, strands 34
resist stretch to limit the overall stretch in upper 30. Strands 34
may also be utilized to distribute forces (e.g., forces from lace
32 and lace apertures 33) to different areas of upper 30.
Accordingly, the orientations, locations, and quantity of strands
34 are selected to provide structural components that are tailored
to a specific purpose. Moreover, the orientations of strands 34
relative to each other and whether strands 34 cross each other may
be utilized to control the directions of stretch in different
portions of upper 30.
[0050] Further Footwear Configurations
[0051] The orientations, locations, and quantity of strands 34 in
FIGS. 1 and 2 are intended to provide an example of a suitable
configuration for footwear 10. In other configurations of footwear
10, various strands 34 or strand groups 51-56 may be absent, or
additional strands 34 or strand groups may be present to provide
further structural components in footwear 10. Referring to FIG. 8A,
strands 34 extending between forefoot region 11 and heel region 13
are absent, which may enhance the longitudinal stretch of footwear
10. A configuration wherein strands 34 extending between lace
apertures 33 and sole structure 20 radiate outward to a greater
degree and cross strands 34 from adjacent strand groups as well as
strand groups that are spaced even further apart is depicted in
FIG. 8B. This configuration may, for example, distribute forces
from lace 32 to an even wider area of upper 30. Referring to FIG.
8C, strands 34 extend downward from only some of lace apertures 33,
but still cross strands 34 from other strand groups. A
configuration that includes additional strands 34 in heel region
13, which may effectively form a heel counter, is depicted in FIG.
8D. Although strands 34 may generally be linear, a configuration
wherein portions of strands 34 are wavy or otherwise non-linear is
depicted in FIG. 8E. As discussed above, strands 34 may resist
stretch in upper 30, but the non-linear areas of strands 34 may
allow some stretch in upper 30. As strands 34 straighten due to the
stretch, however, strands 34 may then resist stretch in upper
30.
[0052] Various aspects relating to strands 34 and layers 41 and 42
in FIG. 3 are intended to provide an example of a suitable
configuration for footwear 10. In other configurations of footwear
10, additional layers or the positions of strands 34 with respect
to layers 41 and 42 may vary. Referring to FIG. 9A, cover layer 42
is absent such that strands 34 are exposed on an exterior of upper
30. In this configuration, adhesives or a thermoplastic polymer
material that infiltrates base layer 41, as discussed above, may be
utilized to secure strands 34 to base layer 41. In FIG. 3, base
layer 41 is substantially planar, whereas cover layer 42 protrudes
outward in the areas of strands 34. Referring to FIG. 9B, both of
layers 41 and 42 protrude outward due to the presence of strands
34. In another configuration, depicted in FIG. 9C, additional
layers 35 and 36 are located to form an interior portion of upper
30 that is adjacent to the void. Although layers 35 and 36 may be
formed from various materials, layer 35 may be a polymer foam layer
that enhances the overall comfort of footwear 10 and layer 36 may
be a moisture-wicking textile that removes perspiration or other
moisture from the area immediately adjacent to the foot. Referring
to FIG. 9D, an additional set of strands 34 is located on an
opposite side of base layer 41, with a backing layer 37 extending
over the additional set of strands 34. This configuration may arise
when an embroidery process is utilized to locate strands 34. A
similar configuration is depicted in FIG. 9E, wherein backing layer
37 has a planar configuration and strands 34 protrude outward from
footwear 10 to a greater degree.
[0053] The running style or preferences of an individual may also
determine the orientations, locations, and quantity of strands 34.
For example, some individuals may have a relatively high degree of
pronation (i.e., an inward roll of the foot), and having a greater
number of strands 34 on lateral side 14 may reduce the degree of
pronation. Some individuals may also prefer greater longitudinal
stretch resistance, and footwear 10 may be modified to include
further strands 34 that extend between regions 11-13 on both sides
14 and 15. Some individuals may also prefer that upper 30 fit more
snugly, which may require adding more strands 34 throughout upper
30. Accordingly, footwear 10 may be customized to the running style
or preferences of an individual through changes in the
orientations, locations, and quantity of strands 34.
FIRST EXAMPLE MANUFACTURING METHOD
[0054] A variety of methods may be utilized to manufacture upper 30
and, particularly, material element 40. As an example, an
embroidery process may be utilized to locate strands 34 relative to
base layer 41. Once strands 34 are positioned, cover layer 42 may
be bonded to base layer 41 and strands 34, thereby securing strands
34 within material element 40. This general process is described in
detail in U.S. patent application Ser. No. 11/442,679, which was
filed in the U.S. Patent and Trademark Office on 25 May 2006 and
entitled Article Of Footwear Having An Upper With Thread Structural
Elements, such prior application being entirely incorporated herein
by reference. As an alternative to an embroidery process, other
stitching processes may be utilized to locate strands 34 relative
to base layer 41, such as computer stitching. Additionally,
processes that involve winding strands 34 around pegs on a frame
around base layer 41 may be utilized to locate strands 34 over base
layer 41. Accordingly, a variety of methods may be utilized to
locate strands 34 relative to base layer 41.
[0055] Footwear comfort is generally enhanced when the surfaces of
upper 30 forming the void have relatively smooth or otherwise
continuous configurations. In other words, seams, protrusions,
ridges, and other discontinuities may cause discomfort to the foot.
Referring to FIG. 3, base layer 41 has a relatively smooth aspect,
whereas cover layer 42 protrudes outward in the areas of strands
34. Similarly, referring to FIG. 9E, backing layer 37 has a
relatively smooth aspect, whereas cover layer 42 protrudes outward
in the areas of strands 34. In contrast, FIGS. 9B and 9D depict
configurations wherein base layer 41 and cover layer 42 protrude
toward an interior of footwear 10 in the areas of strands 34. In
general, the configurations of FIGS. 3 and 9E may impart greater
footwear comfort due to the greater smoothness in the surface
forming the void within upper 30.
[0056] A molding process that may be utilized to form the
configuration of FIG. 3 will now be discussed. With reference to
FIGS. 10A and 11A, a mold 60 is depicted as including a first mold
portion 61 and a second mold portion 62. Each of mold portions 61
and 62 have facing surfaces that, as described below, compress
strands 34 and layers 41 and 42. The surfaces of mold portions 61
and 62 that compress the components of material element 40 each
include materials with different densities and hardnesses. More
particularly, first mold portion 61 includes a material 63 and
second mold portion 62 includes a material 64. In comparison,
material 63 has a lesser hardness and a lesser density than
material 64 and, as a result, material 63 compresses more easily
than material 64. As an example of suitable materials, material 63
may be silicone with a hardness of 15 on the Shore A hardness
scale, whereas material 64 may be silicone with a hardness of 70 on
the Shore A hardness scale. In some configurations of mold 60,
material 63 may have a Shore A hardness less than 40, whereas
material 64 may have a Shore A hardness greater than 40. In other
configurations of mold 60, material 63 may have a Shore A hardness
between 5 and 20, whereas material 64 may have a Shore A hardness
between 40 and 80. A variety of other materials may also be
utilized, including various polymers and foams, such as
ethylvinylacetate and rubber. An advantage to silicone, however,
relates to compression set. More particularly, silicone may go
through repeated molding operations without forming indentations or
other surface irregularities due to repeated compressions.
[0057] In addition to differences in the densities and hardnesses
of materials 63 and 64, the thicknesses may also vary. Referring to
FIGS. 11A-11D, for example, material 63 has greater thickness than
material 64. In configurations where material 63 is silicone with a
hardness of 15 on the Shore A hardness scale and material 64 is
silicone with a hardness of 70 on the Shore A hardness scale,
material 63 may have a thickness of 5 millimeters and material 64
may have a thickness of 2 millimeters. In other configurations of
mold 60, material 63 may have a thickness between 3 and 10
millimeters or more, and material 64 may have a thickness between 1
and 4 millimeters.
[0058] Mold 60 is utilized to form material element 40 from strands
34 and layers 41 and 42. Initially, the components of material
element 40 are located between mold portions 61 and 62, as depicted
in FIGS. 10A and 11A. In order to properly position the components,
a shuttle frame or other device may be utilized. Strands 34 and
layers 41 and 42 are then heated to a temperature that facilitates
bonding between the components, depending upon the specific
materials utilized for layers 41 and 42. Various radiant heaters or
other devices may be utilized to heat the components of material
element 40. In some manufacturing processes, mold 60 may be heated
such that contact between mold 60 and the components of material
element 40 raises the temperature of the components to a level that
facilitates bonding. Radio frequency heating may also be utilized
to heat the components of material element 40.
[0059] Once positioned and heated, mold portions 61 and 62
translate toward each other and begin to close upon the components
such that (a) the surface of first mold portion 61 having material
63 begins to contact cover layer 42 and (b) the surface of second
mold portion 62 having material 64 begins to contact base layer 41,
as depicted in FIGS. 10B and 11B. Mold portions 61 and 62 then
translate further toward each other and compress the components of
material element 40, as depicted in FIGS. 10C and 11C, thereby
bonding the components together.
[0060] Although the components of material element 40 may be formed
from a variety of materials, an advantageous configuration arises
when base layer 41 is formed from a thermoplastic polymer sheet
(e.g., thermoplastic polyurethane). When formed from a
thermoplastic polymer sheet, base layer 41 may be utilized to join
with both cover layer 42 and strands 34. More particularly, the
thermoplastic polymer material of base layer 41 may bond with both
or either of cover layer 42 and strands 34.
[0061] The thermoplastic polymer material base layer 41 may be
utilized to secure the components of material element 40 together.
A thermoplastic polymer material melts or softens when heated and
returns to a solid state when cooled sufficiently. Based upon this
property of thermoplastic polymer materials, heatbonding processes
may be utilized to form a heatbond that joins portions of material
element 40. As utilized herein, the term "heatbonding" or variants
thereof is defined as a securing technique between two elements
that involves a softening or melting of a thermoplastic polymer
material within at least one of the elements such that the
materials of the elements are secured to each other when cooled.
Similarly, the term "heatbond" or variants thereof is defined as
the bond, link, or structure that joins two elements through a
process that involves a softening or melting of a thermoplastic
polymer material within at least one of the elements such that the
materials of the elements are secured to each other when cooled. As
examples, heatbonding may involve (a) the melting or softening of
two elements incorporating thermoplastic polymer materials such
that the thermoplastic polymer materials intermingle with each
other (e.g., diffuse across a boundary layer between the
thermoplastic polymer materials) and are secured together when
cooled; (b) the melting or softening of an element incorporating a
thermoplastic polymer material such that the thermoplastic polymer
material extends into or infiltrates the structure of a strand
(e.g., extends around or bonds with filaments or fibers in the
strand) to secure the elements together when cooled; (c) the
melting or softening of an element incorporating a thermoplastic
polymer material such that the thermoplastic polymer material
extends into or infiltrates the structure of a textile element
(e.g., extends around or bonds with filaments or fibers in the
textile element) to secure the elements together when cooled; and
(d) the melting or softening of an element incorporating a
thermoplastic polymer material such that the thermoplastic polymer
material extends into or infiltrates crevices or cavities formed in
another element (e.g., polymer foam or sheet, plate, structural
device) to secure the elements together when cooled. Heatbonding
may occur when only one element includes a thermoplastic polymer
material or when both elements include thermoplastic polymer
materials. Additionally, heatbonding does not generally involve the
use of stitching or adhesives, but involves directly bonding
elements to each other with heat. In some situations, however,
stitching or adhesives may be utilized to supplement the heatbond
or the joining of elements through heatbonding.
[0062] Although a heatbonding process may be utilized to form a
heatbond that joins base layer 41 to cover layer 42 and strands 34,
the configuration of the heatbond at least partially depends upon
the components of material element 40. As a first example, when
cover layer 42 is a textile, then the thermoplastic polymer
material of base layer 41 may extend around or bond with filaments
in cover layer 42 to secure the components together when cooled. As
a second example, when cover layer 42 is a polymer sheet formed
from a thermoplastic polymer material, then the polymer materials
may intermingle with each other to secure the components together
when cooled. If, however, the thermoplastic polymer material of
cover layer 42 has a melting point that is significantly higher
than the thermoplastic polymer material of base layer 41, then the
thermoplastic polymer material of base layer 41 may extend into the
structure, crevices, or cavities of cover layer 42 to secure the
components together when cooled. As a third example, strands 34 may
be formed from a thread having a plurality of individual filaments
or fibers, and the thermoplastic polymer material of base layer 41
may extend around or bond with the filaments or fibers to secure
the components together when cooled. As a fourth example, strands
34 may be formed to have the configuration of a single filament,
and the thermoplastic polymer material of base layer 41 may extend
around or bond with the filament to secure the components together
when cooled. If, however, the filament is at least partially formed
from a thermoplastic polymer material, then the polymer materials
may intermingle with each other to secure the components together
when cooled. Accordingly, a heatbond may be utilized to join the
components of material element 40 together even when the components
are formed from a diverse range of materials or have one of a
variety of structures.
[0063] As noted above, material 63 has a lesser hardness, a lesser
density, and greater thickness than material 64 and, as a result,
material 63 compresses more easily than material 64. Referring to
FIGS. 10C and 11C, cover layer 42 protrudes into material 63 in the
areas of strands 34, whereas base layer 41 remains substantially
planar. Due to the different compressibilities between materials 63
and 64, material 63 compresses in areas where strands 34 are
present. At this stage, the depth to which base layer 41 protrudes
into material 64 is less than the depth to which cover layer 42
protrudes into material 63. The compressive force of mold 60,
coupled with the elevated temperature of the compressed components
(a) bonds layers 41 and 42 to each other, (b) may bond strands 34
to either of layers 41 and 42, and (c) molds material element 40
such that base layer 41 remains substantially planar and cover
layer 42 protrudes outward in the area of strands 34.
[0064] The different compressibilities of materials 63 and 64 (due
to differences in hardness, density, and thickness) ensures that
cover layer 42 protrudes outward to a greater degree than base
layer 41 in the areas of strands 34. In some configurations, the
relative compressibilities of materials 63 and 64 may allow base
layer 41 to protrude outward to some degree in the areas of strands
34. In general, however, base layer 41 protrudes outward to a
lesser degree than cover layer 42, and base layer 41 may not
protrude outward at all in some configurations. When bonding and
shaping is complete, mold 60 is opened and material element 40 is
removed and permitted to cool, as depicted in FIGS. 10D and 11D. As
a final step in the process, material element 40 may be
incorporated into upper 30 of footwear 10.
[0065] The relative hardnesses, densities, and thicknesses between
materials 63 and 64 may vary considerably to provide different
compressibilities between the surfaces of mold 60. By varying the
hardnesses, densities, and thicknesses, the compressibilities of
the surfaces may be tailored to specific molding operations or
materials. While hardness, density, and thickness may each be
considered, some configurations of mold 60 may have materials 63
and 64 with only different hardnesses, only different densities, or
only different thicknesses. Additionally, some configurations of
mold 60 may have materials 63 and 64 with (a) different hardnesses
and densities, but different thicknesses, (b) different hardnesses
and thicknesses, but different densities, or (c) different
densities and thicknesses, but different hardnesses. Accordingly,
the various properties of material 63 and 64 may be modified in
various ways to achieve different relative compressibilities
between the surfaces of mold 60.
SECOND EXAMPLE MANUFACTURING METHOD
[0066] A similar manufacturing method may be utilized for other
configurations of material element 40. Referring to FIG. 9E, for
example, two sets of strands 34 are located on opposite sides of
base layer 41, with backing layer 37 extending over the additional
set of strands 34. This configuration may arise when an embroidery
process is utilized to locate strands 34. Additionally, backing
layer 37 has a planar configuration.
[0067] A molding process that may be utilized to form the
configuration of FIG. 9E will now be discussed. As with the first
example manufacturing method discussed above, mold 60 is utilized.
Initially, the components of material element 40, including base
layer 41, cover layer 42, strands 34, and backing layer 37, are
located between mold portions 61 and 62, as depicted in FIGS. 12A
and 13A. Once positioned and heated, mold portions 61 and 62
translate toward each other and begin to close upon the components
such that (a) the surface of first mold portion 61 having material
63 begins to contact cover layer 42 and (b) the surface of second
mold portion 62 having material 64 begins to contact backing layer
37, as depicted in FIGS. 12B and 13B. Mold portions 61 and 62 then
translate further toward each other and compress the components of
material element 40, as depicted in FIGS. 12C and 13C, thereby
bonding the components together.
[0068] Although the components of material element 40 may be formed
from a variety of materials, an advantageous configuration arises
when base layer 41 is formed from a thermoplastic polymer sheet
(e.g., thermoplastic polyurethane). When formed from a
thermoplastic polymer sheet, base layer 41 may be utilized to join
with each of cover layer 42, strands 34, and backing layer 37. More
particularly, the thermoplastic polymer material of base layer 41
may be heatbonded with each of cover layer 42, strands 34, and
backing layer 37. As a first example, when backing layer 37 is a
textile, then the thermoplastic polymer material of base layer 41
may extend around or bond with filaments in backing layer 47 to
secure the components together when cooled. As a second example,
when backing layer 37 is a polymer sheet formed from a
thermoplastic polymer material, then the polymer materials may
intermingle with each other to secure the components together when
cooled. If, however, the thermoplastic polymer material of backing
layer 37 has a melting point that is significantly higher than the
thermoplastic polymer material of base layer 41, then the
thermoplastic polymer material of base layer 41 may extend into the
structure, crevices, or cavities of backing layer 37 to secure the
components together when cooled. Accordingly, a heatbond may be
utilized to join the components of material element 40 together
even when the components are formed from a diverse range of
materials or have one of a variety of structures. Moreover, the
thermoplastic polymer material of base layer 41 may be utilized to
join all of the components of material element 40 (e.g., base layer
41, cover layer 42, strands 34, and backing layer 37) together.
[0069] As noted in the first example manufacturing method discussed
above, material 63 has a lesser hardness, a lesser density, and
greater thickness than material 64 and, as a result, material 63
compresses more easily than material 64. Referring to FIGS. 12C and
13C, cover layer 42 protrudes into material 63 in the areas of
strands 34, whereas backing layer 37 remains substantially planar.
When bonding and shaping is complete, mold 60 is opened and
material element 40 is removed and permitted to cool, as depicted
in FIGS. 12D and 13D. Due to the differences in hardness, density,
or thickness of the materials in mold 60, backing layer 37 remains
substantially planar. In some manufacturing processes, strands 34
on different sides of base layer 41 may be offset, as depicted in
FIG. 14. As a final step in the process, material element 40 may be
incorporated into upper 30 of footwear 10.
[0070] Permeable Configurations
[0071] Permeability generally relates to ability of air, water, and
other fluids (whether gaseous or liquid) to pass through or
otherwise permeate material element 40. An advantage of forming
material element 40 to be permeable is that perspiration, humid
air, and heated air, for example, may exit the area around the foot
within upper 30, while cool air may enter upper 30. Base layer 41
may be a thermoplastic polymer sheet in many of the configurations
discussed above. Similarly, either of backing layer 37 and cover
layer 43 may also be a sheet of polymer material. In configurations
where material element 40 includes a sheet of polymer material, the
permeability of material element 40 may be reduced.
[0072] In order to enhance the permeability of material element 40,
a plurality of perforations or apertures may extend through one or
more of base layer 41, backing layer 37, or cover layer 43.
Referring to FIG. 15, for example, a plurality of apertures 38
extend through material element 40 (i.e., through each of layers
37, 41, and 43). Although apertures 38 may be formed in material
element 40 following the manufacturing process for material element
40, apertures 38 may also be formed in each of layers 37, 41, and
43 prior to the manufacturing process.
[0073] As another example of a permeable configuration, apertures
38 extend only through base layer 41 in FIG. 16. As discussed
above, backing layer 37 and cover layer 43 may be formed from
textiles, whereas base layer 41 may be formed from a thermoplastic
polymer sheet. Given that textiles may be inherently permeable,
apertures 38 are formed in base layer 41 in order to enhance the
overall permeability of material element 40. In this configuration,
base layer 41 may be perforated with apertures 38 prior to the
manufacturing process for material element 40.
[0074] Conclusion
[0075] The invention is disclosed above and in the accompanying
figures with reference to a variety of configurations. The purpose
served by the disclosure, however, is to provide an example of the
various features and concepts related to the invention, not to
limit the scope of the invention. One skilled in the relevant art
will recognize that numerous variations and modifications may be
made to the configurations described above without departing from
the scope of the present invention, as defined by the appended
claims.
* * * * *